User Manual
BC500/1000G3
&
BCLab 3.7
User Manual for the BC-box and BC-labG3 Software v3.7
BC250 and BC750,
pretuned for a specific make and model
Examples supported
by the BC250G3
BC500G2 and
BC1000G2, tunable piggyback-box with PC software
Examples of cars
tuned with the BC500/1000
Tech specification
of the BC500G2
Installing the BC250 in an Audi TT
Connector
Specification BC1000G3
Chipdrive Status /
USB Status / BC-box as TuneCard Reader Status
RPM and load resolution (number of cells)
RPM and load resolution (number of cells)
Signal name and selection of log sensor
The Civinco series of electronic
control boxes - The BC - makes it possible to tune your engine without the need
to reprogram the stock ECU (engine control-box). Civinco can offer both
tuneable and ready-tuned boxes which gives you the possibility to optimise your
engine.
The BC-box is available in four
versions:
·
BC250
– Ready tuned box for stock cars with 1-5 cylinder engines. Used as an
alternative for chips and serial programming. No PC software is supplied with
this box.
·
BC500
- Tuneable box for cars with 1-5 cylinder engines. Includes PC software
enabling full tuning of engine parameters. Tunes fuel, ignition, extra
injectors, NOS, shift light, water injection etc.
·
BC750
– Ready tuned box for stock cars with 6-10 cylinder engines. Used as an
alternative for chips and serial programming. No PC software is supplied with
this box.
·
BC1000
- Tuneable box for cars with 6-10 cylinder engines. Includes PC software
enabling full tuning of engine parameters. Tunes fuel, ignition, extra
injectors, NOS, shift light, water injection etc.
The BC-box is connected between the
stock ECU and the main harness, or it can be connected directly to sensors,
injectors etc. This makes it possible to alter some in- and output signals
which is necessary in all electronic tuning. The basic principle is that the
BC-box will increase the boost pressure and add more fuel and at the same time
"hide" this information from the ECU. In this way the ECU controls
the engine during normal operation such as cold-start and idle etc but the
BC-box controls the engine at high power. Common to all versions of the BC-box
is that all tuning data is stored on a TuneCard (memory card) which is easily
exchanged while driving to give the engine different behaviour such as;
imobilizer, rpm-limiter, exotic fuels, max fuel efficiency or maximum power.
TuneCard inside the car BC1000 with harness for Dodge Viper
Examples of supported functions:
·
Tuning
ignition and fuel as function of rpm and boost
·
Tuning
the boost at the same time as the boost signal is hidden from the ECU
·
Activation
of nitrous, water injection, extra injectors, shiftlight
·
Mass
airflow simulation using auxiliary MAP sensor
·
Controlling
larger than stock fuel injectors
·
All
tuning data is stored on a Tunecard memorycard (3 cards supplied)
·
All
tuning is done using the easy-to-use Windows BCLab program
·
The
BC-box is updated with tuning data using the Tunecards or by directly
connecting the BC-box to the PC serial port
·
Engine
data can be logged and later analysed as graphs in BCLab
·
Auxiliary
analog, digital and PWM-signals can be used to control or logg extra devices
·
Sold
as a kit containing; BC-box, wiring, programming cable, bypass connector and an
installation CD
What’s been
added in generation 3 is:
·
Complete
3D map for fuel and ignition.
o Chose able size on both maps.
o Able to choose how close it’s between load and rpm cells.
·
One
extra PWM-output in BC1000G3
·
One or
two completely tuneable digital outputs to control Vanos, Vtec, gear indicator
etc.
·
Cold
start function for easy tuning of E85.
Civinco are responsible that the engine management system is
working correctly at delivery, presupposed it has been correctly
installed. Civinco offers a 10 year warranty. Civinco does not take responsibility for damage on engine, car or person in connection to the use of Civinco’s system
The
BC250/750 is a new type of tuning box for turbo engines. It's a plug-in type
box which is connected to engine sensors and actuators, such as fuel injectors,
camshaft sensor, manifold pressure sensor etc.
TuneCard
The
BC250/750 can be loaded with different tuning parameters for different
situations. The tuning parameters are stored on a memory card,
"TuneCard". To switch the tuning just insert the card in the Bc-box.
The new card is read in 5 seconds and the new tuning is immediately active. The
card can then be removed from the BC-box. The cards can be inserted while the
engine is running.
Used as an
alternative for tuning chips or serial programming
Simple
installation, no need to modify the stock equipment
Plug-in
connectors for most sensors/actuators
No need to
break the seal on the stock ECU
Simple to
build back to stock
The BC-box
can be used in another car (may need different tuning)
Delivered
with 3 TuneCard: Stock (no tuning), Economy (more power and best mileage) and
Sport (maximum power)
Special
tuning parameters available, such as: Winter, Super Sport, StreetRace,
Imobilizer, RPM-limit etc.
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Original 150 hk - BC250 197 hk |
Original 150 hk - BC250 197 hk |
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Original 225 hk - BC250 255 hk |
Original 150 hk - BC250 197 hk |
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Original 193-300 hk - BC250 240-375 hk |
Original 163-200 hk - BC250 197-240 hk |
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Original 55-75 hk - BC250 62-80
hk |
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The
BC250/750 is supplied with a car specific electrical harness, installation
instructions with pictures and 3 TuneCards with different power levels. Extra
blank TuneCards are sold separately.
The BC250
is available for most VAG 1.8Turbo engines 1996-2004 (Audi, VW, Seat, Skoda),
Volvo S40&V70 Turbo and the Smart Turbo.
The BC750
is available for the Dodge Viper 1996 and forward
Please refer
to our website www.civinco.com for the
latest manuals and tuning examples for the specific model.
The
BC500/1000 differs from the BC250/750 in that they are not optimised for a
specific engine but can be used on just about any car/engine. This also
includes engines with a larger than stock turbo, or natural aspirated engines
with installed turbo or supercharger. In these cases you must be able to tune
the relevant tuning parameters yourself using the BCLab software. The electrical
harness differs in that it is a more general harness. The harness can be
supplied with or without certain plugs, such as injector plugs etc.
BC500/1000
features not available in the BC250/750:
•
Activation
of nitrous, water injection, extra injectors, gearshift indicator
•
Mass
airflow simulation using an extra MAP-sensor
•
Control
larger than stock injectors
•
Tuned
with the BCLab PC software
•
Possibility
to log data and afterwards view graphs in Windows
•
Up to
16 inputs and 16 outputs
•
Extra
analog/digital and PWM in/outputs to control or log auxiliary equipment
Audi S2 -
Larger than stock turbo
Audi S4 - Stock
Arctic Cat
(snowmobile) – Stock
BMW 3-series E36,
E46, E90
Chrysler 300C - Hemi V8
Turbo
Dodge Viper
- Supercharger and nitrous
Dodge Viper – Turbo
Dodge SRT10 – Supercharged
Honda Civic
CRX 1.6 - Supercharger, racing fuel and nitrous
Honda Civic
CRX 1.6 - Turbo
Mazda Miata
– Turbo
Mazda Miata
- Supercharged
Mitsubishi
3000 GT - Stock
Nissan 300
ZX – Stock
Porsche 944
turbo
Porsche 944
naturally aspirated driven on E85
Skoda
Octavia RS - Larger than stock turbo
Subaru
Impreza - Larger than stock turbo
Suzuki Hayabusa
(MC) - Turbo
Toyota Supra -
Single turbo
Toyota
Celica - Larger than stock turbo
Toyota MR2 -
Stock
Volvo S40 -
Turbo
Volvo 740
Turbo - Stock
Volvo 360 –
Turbo
Volvo 850 –
larger than stock turbo MAF-sim
VW Golf V6
- Turbo and Mass airflow simulation
There are 4
LEDs above the TuneCard slot. These are from the left:
1.
Green
power - The BC is powered up
2.
Red
This LED will light up at preselected rpm chosen in BCLab, see section Box settings-"RPM ind"
3.
Red
Read/Write operation in progress. Also LED for error codes
4.
Green
steady: TuneCard read/write operation completed. Flashing (two flashes
repeatedly): TuneCard read/write operation completed and the slave-PCB data is
verified
The button next to the
LEDs is used like this:
If the
button is held pressed while a TuneCard is inserted the current BC-box data is
transferred to the TuneCard, - the TuneCard data is replaced by the data in the
BC-box.
In the
BCLab software under section "BC-box settings-Advanced-BC
Digital I/O mode" you will enter which main mode to be used and thus also which connector
pins to use. You will also under sections Ignition load, Fuel load and PWM load
which analog input to use for load measurement and base the tuning on.If the
engine has a MAP-sensor you will specify which pin this is connected to. Other
engines may be better off basing the tuning on the TP-sensor.
Digital in/outputs
The BC500 has 6 digital
in/output-pairs (12 pins), where every input has its associated output. These
are called: FuelA-FuelE(5 fuel channels), IgnitionA-IgnitionB (2 Ignition
channels) and PWM (1 boost channel). One of the signal-pairs can be used for
different functions and cannot be used simultaneously. This is FuelE, IgnitionB
and PWM. The reason for organising the in/outputs in pairs is that when
connecting a bypass-plug (instead of the BC-box) then all channels will be
short-circuited and the signals are unaffected (the engine behaves stock). When
the BC-box is connected, the box will modify the signals according to the
Tuning parameters and send them to the paired output.
The BC-box can thus be run in
different modes where the pins have different functions:
·
Mode
o
4 Fuel
in/out, FuelA-FuelD, pins 15-22
o
2
Ignition in/out, IgnitionA-IgnitionB, pins 11-14
o
Boost
control out, PWM_OUT, pin 5
·
Mode2
- no longer activated
·
Mode3
o
5 Fuel
in/out, FuelA-FuelE, pins 15-22 & 11-12
o
1
Ignition in/out, IgnitionA, pins 13-14
o
Boost
control out, PWM_OUT, pin 5
·
Mode4
- no longer activated
·
Mode5
o
4 Fuel
in/out, FuelA-FuelD, pins 15-22
o
1 Ignition
in/out, IgnitionA, pins 13-14
o
Boost
control in/out, PWM_OUT/IN, pins 11-12
The rpm
calculation is always based on
IgnitionA, this signal can be taken from several places as long as you know how
many pulses per rev it has. Both IgnitionA and IgnitionB can be connected to
crank/cam signals or ECU signals to the Ignition module. The signals must be of
the type 0V to 5-20V. Sometimes it is necessary to use an amplifier to achieve
the correct voltage level.
PWM Out
The BC500G3
has one PWM output, PWM_OUT which in mode 1&3 is used to control the boost,
but in mode5 can be used for other purposes. In the BC1000G3 there is an extra
PWM output that can be tuned depending on rpm or load.
Digital output
The BC500G3
has got one pure digital output, Digital1_OUT. This can for example be used to
control:
·
Gearshift
indicator
·
VANOS,
VTEC etc.
·
Other
accessories that you want to activate at a specific rpm or load.
The
BC1000G3 has an extra digital output, Digital2_OUT.
Analog in/outputs
The BC has two analog in/output pairs where every input has
its associated output. These are called: Analog1 and Analog2. The basic idea
with this is to limit the analog sensor signal (rpm dependant)l to a value
which represents the stock manifold pressure or Mass airflow. In the BCLab
software, you will select which analog sensor signal to base the tuning on.
This selection is done at pages: Ignition load, Fuel load and PWM load.
Analog input
The BC has two
more analog inputs which are pure inputs, thus the total is 4 analog inputs.
In the
BC1000G3 all the in-outputs are doubled
Power connections: Pin 1, 2, 23, 24:
1, 23 Grounding. It's
very important to achieve a good solid grounding. Use shortest possible wires
and always use both wires.
24 12V power.
Connect this to a 12V power source which is switched by the ignition. The
current is less than 0.5 Amps.
2 5V output to
power auxiliary sensors, max 50mA.
Fuel injectors: Pins 15, 16, 17, 18, 19, 20, 21, 22:
The BC250/500 can connect up to 5 injectors (cylinders A-E). You will
connect the BC between the ECU and the injector. The in/outputs must be
connected in pairs according to: A(22-21), B(20-19), C(18-17), D(16-15),
E(12-11).
(12), 16, 18, 20, 22 Fuel signal inputs to the BC-box from the ECU. The fuel signal shall be
connected to the BC-box instead of the injector. Pin 11,12 FI_E_IN/OUT is only
used on 5cylinder engines (instead of IgnitionB).
(11), 15, 17, 19, 21 Injector driver output from the BC-box. The injectors are connected here
instead of to the ECU.
Ignition : Pin 11, 12, 13,
14:
It's possible to control 2 ignition
modules at the same time, IGNITION_A and IGNITION_B with their in- and outputs.
If only one ignition channel is required, then IGNITION_B can be used for other
purposes such as: a 5th fuel channel or control of the boost valve.
In many cases there is no need to tune the
ignition, in such cases it's sufficient to only sense the rpm. This signal can
be from the ignition system, the camsensor or the cranksensor. Depending on the
used signal you may have to connect an amplifier to achieve the correct voltage
level.
12, 14 Ignition signal inputs to the BC-box from the ECU. The ignition signal
shall be connected to the BC-box instead of the ignition module.
11, 13 Ignition outputs from the BC-box to the ignition modules (The BC-box
cannot drive ignition coils directly without an ignition module). The ignition
modules are connected here instead of to the ECU. They have to be connected
input-output for each ignition module as: A(14-13), B(12-11).
Analog signals: pins 4, 6, 8, 10, 7, 9:
10, 8, 6, 4 0-5V
analog signals Analog1-4. Normally used for measuring Manifold absolute pressure, Mass airflow,
knocksensor, throttle position or temperature.The BC-box can use all these
signals to tune fuel, boost, ignition etc. in the BCLab software.
9 Analog1-output, an analog output
signal which can be voltage limited. It can be used to hide the high MAP or
Mass airflow value from the ECU. The output voltage is the same as the input
voltage at pin8(analog1) up to a certain maximum value. Any input above this
maximum value will only produce that maximum output value. The maximum value is
selected in BCLab at page Analog out-Analog1 out.
7 Analog2-output. This output can be controlled
in three ways:
The
output can be a function of the Analog2 input value. For every input there will
be a certain output according to how you have tuned this function in BCLab.
The
output can be voltage limited in the same manner as analog1.
When
controlling the boost via PWM_IN/OUT (pins 11,12) this signal can be voltage
limited in a smarter way called limit trim.
Driver outputs: pins 3, 5,11:
The boost valve is controlled by a
PWM output. Which pin you use for this is selected in the BCLab-Configurations.
The PWM output can also be used to control other devices compatible with the
PWM-type output (lamps, valves, motors etc.) The outputs can handle 3 Amps.
11 PWM output. Normally used to control
the boostvalve when the ECU boost control signal is connected to the PWM_IN
BC-box input.
5 PWM output. Can be used to control
the boost valve.
3 Digital
output. Can be used to control gearshift indicator, vanos, vtec etc.
PWM input: pin 12:
12 PWM input. Can be used to connect
the ECU boost control signal to the BC-box. This is used for logging purposes
or when you wish to use the Analog2-out "limit trim" function.
The BC-box
can be installed in three different ways.
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Example 1: ECU
The BC-box is connected directly to
injectors, sensors and boost control valve in the engine bay. In this type of
installation the BC-box does not tune the ignition. The camsensor signal is
used to calculate the rpm. This installation is used with the VAG 1.8T
engines, Smart, Volvo and most custom projects. |
Example 2: ECU
The BC-box is connected to the ECU connector
or another suitable connector in the stock electrical harness. This
installation is used in the Dodge Viper generation 2. |
Example 3: In those cases where there are no suitable
connectors to use we use a general harness without connectors. At suitable
places in the stock electrical harness, the stock wires are cut and soldered
to the BC harness. This installation is used with the Honda CRX and Mazda
Miata. |
Installation of BC
in an Audi TT 1.8 Turbo.
Installation
time 1.5 hrs.
|
No |
Connection |
Type |
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1-4 |
Fuel
injectors |
Plug-in |
|
5 |
Throttle
position sensor |
Split
connector |
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6 |
Boost
control |
Plug-in |
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7 |
Mass
airflow sensor |
Cable
connector |
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8 |
Camsensor |
Plug in |
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9 |
MAP
sensor |
Cable
connector |
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Check our website www.civinco.com for the latest installation manuals and tuning examples.
The PC
software BCLab is used to tune the BC500/1000. This software is also available
as an upgrade to the BC250/750 which is delivered with ready tuned TuneCards
for those users who wish to do their own tuning. In the below simplified
example we will assume that we want to increase power by adjusting the maximum
boost. The BC500/1000 can just as well be used to tune a car with an
aftermarket turbo/supercharger installation. The tuning principles are the same
but more tuning parameters may need adjustment.
The basic
working principles for the BC-box is to measure the engine rpm, boost pressure,
Mass airflow and/or manifold pressure. Depending on the amount of air entering
the engine the ECU will supply the correct amount of fuel. When opening the
throttle more air will enter the engine and thus the ECU will calculate a
higher amount of fuel. Depending on the rpm and airflow the ECU will also
calculate the ignition advance.The difference between boost pressure and manifold
pressure is that the throttle is between them. When opening the throttle more
of the boost pressure will reach the manifold (and engine).
The turbo
is capable of generating boost depending on rpm, which in turn determines the
airflow into the engine. In order to regulate the boost, the ECU uses a boost
control valve to adjust the boost pressure. Close to the turbo there is a boost
pressure sensor that sends a feedback signal to the ECU of the actual boost
pressure. The ECU "knows" which boost to expect with a given
boost control valve position (signal) and also knows the maximum allowable
boost.
That's why
we must "hide" the real (higher) boost from the ECU.
The BC-box
now increases the signal to the boost control valve in order to increase the
boost pressure above the stock maximum level. In order to keep the ECU happy we
must limit the boost sensor signal to the ECU so that it cannot "see"
a higher boost level than stock. The Mass airflow signal to the ECU is limited
in the same manner. If the ECU would be allowed to "see" the
higher airflow into the engine it would detect an abnormal situation and set a
fault light and shut down the engine. Since the engine with the higher boost
pressure will see a higher airflow, the BC-box must supply more fuel, adjust
the ignition and completely take control of the boost valve.
The amount
of fuel is determined by engine rpm and manifold pressure (or Mass airflow).
You will tune the fuel for every rpm and every manifold pressure. It's like a
grid where the number of cells equals (number of rpm positions)x(number of
manifold pressure positions).
For
example: we only measure 3 rpm positions: 0-2000, 2001-4000 and 4001-6000. At
the same time we only measure 3 manifold pressure positions. This means we must
tune 9 different cells in the grid. But the BC actually measures 256x256=65536
cells. Luckily we don't have to tune all of these 65536 cells, the BC will
automatically do the calculation for us. Instead we will tune the rpm and
airflow separately and the BC-box will calculate all other combinations.
|
Manifold pressure |
Fuel Enrichment depending on load
(load table) |
Calculated fuel
values depending on boost pressure and rpm. |
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2-3 bar |
10 ms |
Fuel value 7 |
Fuel value 8 |
Fuel value 9 |
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1-2 bar |
2 ms |
Fuel value 4 |
Fuel value 5 |
Fuel value 6 |
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0-1 bar |
0 ms |
Fuel value 1 |
Fuel value 2 |
Fuel value 3 |
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More fuel enrichment depending on rpm |
100 % |
100 % |
110% |
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rpm |
0-2000 rpm |
2001-4000 rpm |
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